Crank, Pistons and Rods, Dismantling

1. Remove oil pan:
- Remove oil filter.
- Remove pan carefully by tapping it loose with a rubber mallet.





2. Remove oil pan suction pipe:
- Clean and inspect pipe and filter.
- Remove suction pipe O-ring.
- Remove oil passage O-rings.





3. Remove intermediate section:
- Using the illustration above, undo intermediate section 7 mm and 8 mm bolts in sequence from number 6 to number 1.
- Then undo all 10 mm bolts from number 6 to number 1.
- Tap intermediate section loose carefully with a plastic mallet.
- Remove crankshaft rear seal.

CAUTION: Do not allow crankshaft to rotate.





4. Remove big end bearing caps:
- Check markings on bearing caps and connecting rods.
Mark with a number punch or die as necessary.
- Check centering of bearing shells in connecting rods and caps.

CAUTION:
- Do not mix up different crankshaft bearing shells.
- Do not rotate crankshaft.





5. Lift crankshaft out of cylinder block:
- Support crankshaft in suitable V-blocks on two outermost main journals.
- Remove remaining main bearing shells from block.
- Mark position of thrust bearing.

CAUTION: Do not mix up different main bearing shells.





6. Remove pistons from block:
- In order to overcome ring friction press pistons carefully out by hand.
- Taking care not to scratch bores, remove pistons and connecting rods from bores.





7. Clean joint faces:
- Clean joint faces on cylinder block, intermediate section and oil pan.
- Scrape surfaces clean carefully with plastic putty knife.
- Use gasket remover if necessary, part No. 1 161 340-3, or equivalent.

NOTE: A fume hood or extractor must be used when using gasket remover.